Variational mode decomposition provides a feasible method for non-stationary signal analysis, but the method is still not adaptive, which greatly limits the wide application of the method. Therefor...

A new fault diagnosis method based on adaptive spectrum mode extraction

The demand for cost-effective, reliable and safe machinery operation requires accurate fault detection and classification to achieve an efficient maintenance strategy and increase performance. Furthermore, in strategic sectors such as the oil and gas industry, fault prediction plays a key role to extend component lifetime and reduce unplanned equipment thus preventing costly breakdowns and plant shutdowns. This paper presents the preliminary development of a simple and easy to implement machine learning (ML) model for early fault prediction of a centrifugal pump in the oil and gas industry. The data analysis is based on real-life historical data from process and equipment sensors mounted on the selected machinery. The raw sensor data, mainly from temperature, pressure and vibrations probes, are denoised, pre-processed and successively coded to train the model. To validate the learning capabilities of the ML model, two different algorithms—the Support Vector Machine (SVM) and the Multilayer Perceptron (MLP)—are implemented in KNIME platform. Based on these algorithms, potential faults are successfully recognized and classified ensuring good prediction accuracy. Indeed, results from this preliminary work show that the model allows us to properly detect the trends of system deviations from normal operation behavior and generate fault prediction alerts as a maintenance decision support system for operatives, aiming at avoiding possible incoming failures.

Machine Learning Approach Using MLP and SVM Algorithms for the Fault Prediction of a Centrifugal Pump in the Oil and Gas Industry

Artificial intelligence (AI)-based rotor fault diagnosis (RFD) poses a variety of challenges to the prognostics and health management (PHM) of the Industry 4.0 revolution. Rotor faults have drawn more attention from the AI research community in terms of utilizing fault-specific characteristics in its feature engineering, compared to any other rotating machinery faults. While the rotor faults, specifically structural rotor faults (SRF), have proven to be the root cause of most of the rotating machinery issues, the research in this field largely revolves around bearing and gear faults. Within this scenario, this paper is the first of its kind to attempt to review and define the role of AI in RFD and provides an all-encompassing review of rotor faults for the researchers and academics. In addition, this study is unique in three ways: (i) it emphasizes the use of fault-specific characteristic features with AI, (ii) it is grounded in fault-wise analysis rather than component-wise analysis with appropriate fault categorization, and (iii) it portrays the current research and analysis in accordance with different phases of an AI-based RFD framework. Finally, the section on future research directions is aimed at bridging the gap between a laboratory-based solution and a real-world industrial solution for RFD.

Role of artificial intelligence in rotor fault diagnosis: a comprehensive review

A convolutional neural network based degradation indicator construction and health prognosis using bidirectional long short-term memory network for rolling bearings

Accurate health evaluation is crucial to reliable operation of complex degradation systems. Although traditional machine learning methods such as artificial neural network (ANN) and support vector machine (SVM) have been used widely, state assessment schemes based on a single classification model still suffer from low multiclass classification efficiency, high variance, and deviation. To solve these problems, this article proposes a novel health evaluation method based on stacking ensemble learning and generalized multiclass support vector machine (GMSVM) algorithm. The proposed health evaluation framework includes three parts: 1) abnormal value elimination and missing value processing are applied for multiple sensor data; 2) statistical features are extracted from the observed data and the Pearson correlation coefficient is applied for feature selection; and 3) ensemble generalized multiclass support vector machines (EGMSVMs) are utilized to evaluate the health situation of a degradation system. Unlike the binary classifiers and deep-learning-based classifiers, EGMSVMs utilize the stacking-based method to combine several GMSVMs as submodels and random forest as a metamodel, and the metamodel ensembles the results of submodels to reach a satisfied performance. Compared to traditional SVM- and ANN-based algorithms, EGMSVMs, in processing multiclass problems, achieve high efficiency and, meanwhile, low variance and deviation. The proposed method is verified using a hydraulic test rig. The experimental results show the feasibility and applicability of the proposed health evaluation framework.

Ensemble Generalized Multiclass Support-Vector-Machine-Based Health Evaluation of Complex Degradation Systems

The data-driven fault indicator for rotating machinery is designed to reveal the possible fault scenarios from the observed statistical vibration signals. This study develops a novel ensemble extreme learning machine (EELM) network to replace the conventional layout by combining binary classifiers (e.g., binary relevance) for compound-fault diagnosis of rotating machinery. The proposed EELMs consist of two sub-networks, namely, the first extreme learning machine (ELM) for clustering, and the second for multi-label classification. The first network generates the Euclidean distance representations from each point to every centroid with unsupervised clustering, and the second identifies potential output tags through multiple-output-node multi-label learning. Compared to the existing multi-label classifiers (e.g., multi-label radial basis function, rank support vector machine, back-propagation multi-label learning, and binary classifiers with binary relevance), the theoretical verification reveals EELMs perform the best in hamming loss, one-error, training time, and achieves the best overall evaluation for the two real-world databases (e.g., Yeast and Image). Regarding the real test for the compound-fault diagnosis of rotating machinery, this paper applies the particle swarm optimization-based variational mode decomposition to decompose the raw vibration signals into a series of intrinsic modes, and selects ten time-domain indicators and five frequency-domain statistical characteristics for feature extraction. The experimental results illustrate that the EELM-based fault diagnosis method achieves the best overall performance.

Zhen Li

Papers

Ensemble extreme learning machines for compound-fault diagnosis of rotating machinery